Patio enclosure support member

ABSTRACT

A support member for a sunroom or patio enclosure comprises a pair of interfitting elongated U-shaped channel members that are latched resiliently together to form a hollow rectangular tube. Side panels of a first channel member fit inside side panels of a second channel member and extend to a position immediately adjacent the back panel of the second channel member, so the side panels overlap and reinforce each other for a substantial portion of the width of the side panels. The channel members are latched together by a latch mechanism comprising slots in the front edges of the inner side panels of the first channel member that engage ridges positioned in the outer side panels immediately adjacent the back panel of the second channel member. The latch automatically engages when the two channel members are slid together and resists disengagement. The latch provides for maximum overlap of the side panels of the two channel members and positions the latch mechanism adjacent the back panel of the second channel members so it does not obstruct panels or other structures that might be inserted in the second channel member.

CROSS-REFERENCES TO RELATED APPLICATIONS

Not applicable

BACKGROUND OF THE INVENTION

Patio enclosures and sunrooms are often added to new or existing homes or buildings by the use of prefabricated hollow metal beams and columns that are bolted together, with windows, screens, or solid panels being supported by the structural members. Aluminum extrusions are popular components of the support members. Sometimes the aluminum extrusions are formed in two U-shaped sections, with the sections being fitted together to form a hollow rectangular tube. In common practice, the U-shaped sections overlap slightly and are screwed together along the length of the tube to hold the U-shaped sections together. This is time consuming and expensive.

Some constructions use structural members wherein opposing U-shaped sections are clipped together by an interlocking latch mechanism. However, the resulting hollow beam is generally weak and does not withstand substantial wind stress or other stress without reinforcing the attachment mechanism by the additional use of screws.

An object of the present invention is to provide an improved structural member wherein two channel members latch securely together and provide a strong, reinforced structure that provides excellent strength characteristics and does not require screws to hold the structure together.

BRIEF SUMMARY OF THE INVENTION

In accordance with the present invention, a support member for a sunroom or patio enclosure comprises a pair of interfitting elongated U-shaped channel members, each having a pair of spaced parallel side panels and a back panel extending at right angles between rear edges of the side panels. The open ends of the two channel members fit together, with the side panels overlapping for a substantial portion of the width of the side panels. The side panels of a first channel member fit inside side panels of a second channel member and extend to a position immediately adjacent the back panel of the second channel member. A latch mechanism comprising an interlocking projection and slot arrangement engages the front edge of the inner side panels with latch members positioned immediately adjacent the back panel of the other channel member. The latch automatically engages when the two channel members are slid together and resists disengagement. The latch member provides for maximum overlap of the side panels of the two channel members and positions the latch mechanism adjacent the back panel of the second channel members so it does not obstruct panels or other structures that might be inserted in the second channel member. The structural members of the present invention are easy to install by simply clipping the channel members together, and once installed they provide a rigid, secure hollow rectangular support member that has very desirable strength characteristics.

These and other features of the present invention will hereinafter appear and for purposes of illustration but not of limitation, a preferred embodiment of the present invention is described below and shown in the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a sunroom, patio, or screen enclosure constructed in accordance with the present invention.

FIG. 2A is an exploded view showing two channel member components of the structural member of the present invention in an unassembled position.

FIG. 2B is a cross sectional view taken along lines 2-2 of the channel member of the present invention, showing the elements of FIG. 2A in assembled condition.

FIG. 3 is a cross sectional view taken along lines 3-3 of FIG. 1.

FIG. 4 is a perspective view of the structural member of FIG. 2.

FIG. 5 is a cross sectional view of the structural member of FIG. 2, showing a panel frame adapter that mounts on a side of the structural member.

FIG. 6 is a cross sectional view of a structural member in accordance with the present invention, wherein the structural member incorporates a thermal break between outside and inside surfaces thereof.

FIG. 7 is a cross sectional view similar to FIG. 4, showing panel adaptors mounted on opposite sides of the structural member.

FIG. 8 is a cross sectional view showing a corner post having channel sections of the present invention mounted therein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A preferred embodiment of the present invention will be described below by reference to the attached drawings. For exemplary purposes, the reference to structural member may refer to either a post or a beam, and the beams may be incorporated in a sidewall or a roof structure. The structure itself may be a patio enclosure, a sunroom, a screened porch, or any other type of partial or complete enclosure.

Referring now to the drawings, an enclosure 10 constructed in accordance with the present invention is shown in FIG. 1. This enclosure may be a sunroom, patio, screened porch, or other type of enclosure. The enclosure may be attached to the side of a house or may be free standing.

Enclosure 10 comprises a number of structural members 12 that form the frame of the structure. Structural members 12 include spaced vertical posts 14 and horizontal beams 16 extending between and supported by the posts. Roof beams 18 define a ceiling to the enclosure. The space between the beams and posts may be open, or it may be filled at least partly with solid panels 20, or with windows 22, and/or with screens 24.

Structural members 12, shown disassembled in FIG. 2A and assembled in FIG. 2B, comprise a pair of opposed elongated channel members 26 and 28. Each channel member has a generally rectangular configuration with one open side, giving each channel member a generally U-shaped appearance. A first channel member 26 has a back panel 30 and two spaced side panels 32 attached to the back panel at rear edges 34 thereof and extend forwardly therefrom to front edges 36.

A second channel member 28 similarly includes a back panel 38 and spaced side panels 40 extending forwardly (the direction away from the back panel) from opposite edges of the back panel. The side panels include front edges 42 and rear edges 44 attached to the back panel. Side panels 40 are spaced slightly further apart than side panels 32, such that side panels 32 fit inside side panels 40 in abutting engagement therewith when the two channels are fitted together. A ridge 48 along a rear portion of side panels 32 extends in front of the front edges 42 of second channel member 28 and limits the distance that the channel members can extend into engagement with each other.

When the channels are fitted together, they are locked together by a resilient latch mechanism 50. Latch mechanism 50 includes an outwardly facing groove 52 in an enlarged portion 54 at the front edges 36 of side panels 32. Grooves 52 fit over and engage inwardly extending ridges 56 on the inner sides of side panels 40 at a position spaced relatively closely to back panel 38. Spacing ridges 56 substantially rearwardly from forward edges 42 makes it possible to slide a panel 60 substantially into the channel member, as shown in FIG. 3, so that the channel member can be used as a frame for the panel.

In order to facilitate the engagement of latch mechanism 50, the front edge 36 of channel member 26 includes an outwardly and inwardly inclined beveled surface 62 adjacent groove 52. Beveled surface 62 engages ridges 56 as the channel members are fitted together, and this beveled surface acts as a cam, resiliently deflecting the forward edges of side panels 32 inwardly until the grooves 52 fit over ridges 56 and lock the two channel sections together. When thus locked, the channel sections do not readily disengage.

When the channel members are latched together, as shown in FIG. 2B, they form a square or otherwise rectangular hollow beam, with side panels 32 and 40 overlapping and providing mutual reinforcement for each other for a substantial portion of the length of the side panels. In a typical installation, the side panels overlap for about 1 inch of a 2 inch square beam (which is typical). The distance of overlap could be somewhat more or somewhat less but is generally maximized in order to provide a maximum amount of overlap and reinforcement of the two side panels. Prior art beams having side panels that overlap by about one-half inch have been found to provide substantially less strength than the beams of the present invention. Thus, for a two inch sidewall, it is believed that the side panels should overlap by more than one-half inch, and preferably by at least ¾ inch or more.

Other features of the structural member of the present invention include longitudinal grooves 64 adjacent corner edges for accommodating a screen 66, shown schematically in FIG. 2B. Typically, the grooves would face outwardly, so that the screen lays across the outer surface of the support members.

The back panels of the channel members include spaced circular grooves 68. These receive screws for attaching structural members across the ends of other structural members. In addition, the screw grooves serve as channels for receiving panel adapters 70, as shown in FIG. 5 and FIG. 7. Channel adapters 70 include a back panel 72 and spaced perpendicular side flanges 74, with mating ribs 76 having rounded beads on the edges running along outer sides of the back panels. Ribs 76 engage screw grooves 64, so that the panel adapters can be slid longitudinally into locking engagement in the sides of the structural members. Thus, the panel adapters can cover edges of solid panels 60 and hold them in place adjacent the structural member. As shown in FIG. 3, it is also possible to use just one channel member 28 for the purpose of forming a top beam over the channel member. In this case, side panels 62 will fit over the top edge of the solid panel, and ridges 56 will serve as a stop and limit the inward movement of the panels 60.

Another embodiment of the present invention is shown in FIG. 6. In this embodiment, the structural member, instead of being a conventional two inch square member, is a two inch by three inch rectangular member, with inner and outer sides of the member being separated and connected together by a non-conductive material 78. This non-conductive material fits in C-shaped opposing grooves 80 in the opposing sections. The non-conducting material can be fused into place by heat or friction. A rectangular piece of foam board insulation 82 can fit in the interior of structural member 84 to further improve the all weather capabilities of the structural member. Structural member 84 is otherwise similar in configuration and function to the structural member described above.

The manner in which a corner is formed in an enclosure is shown in FIG. 8. A corner post 86 forms the corner of the enclosure. Corner post 86 is a solid rectangular extrusion having a pair of spaced parallel flanges 88 and 90 extending perpendicularly from one side wall and having spaced flanges 92 and 94 extending perpendicularly from an adjacent side wall. One section 26 of a structural member may be inserted between each of the pairs of parallel flanges, in the manner shown in FIG. 8. The flanges can have ridges similar to ridges 56 in order to lock the channel members 26 in place against the posts.

In order to insert windows into the rectangular spaces between spaced beams and columns, a window having an outwardly extending flange on one side is simply fitted into the opening and attached in place by screws or the like.

An advantage of the present invention is that an enclosure can be formed in separate panels and the panels can thereafter be clipped together along their side edges simply by pressing the panel sections together, with the side panels of one channel member engaging the side panels of an adjacent channel member. This way, the panels can all be preconfigured and then simply clipped together to erect the enclosure at the construction site.

The structural components of the present invention are desirably formed of extruded aluminum and may be finished as desired, with exposed surfaces being desirably painted or otherwise coated.

It should be understood that the foregoing is merely representative of the preferred practice of the present invention and that various changes and modifications of the arrangements and details of construction of the embodiment disclosed herein may be made without departing from the spirit and scope of the present invention. 

1. A support member for a sunroom or patio enclosure comprising a pair of interfitting elongated U-shaped metal channel members, each channel member having a pair of spaced parallel side panels and a back panel extending at right angles between rear edges of the side panels, the channel members fitting together to form a rectangular tube with the legs of the two channel members abutting in overlapping engagement, the side panels of a first channel member comprising inner panels and fitting inside the side panels of the other channel member, which legs comprise outer side panels, the support member further including a latch mechanism that engages front edges of the inner side panels with rear inside portions of the outer side panels such that the channel members latch together when the two channel members are pressed together, the latch resisting separation of the two channel members once they are latched together, the side panels overlapping for a substantial portion of the width of the side panels.
 2. A support member as in claim 1 wherein the inside side panels are of approximately equal width.
 3. A support member as in claim 2 wherein the latch mechanism comprises outwardly facing grooves at outer ends of the inner side panels and inwardly extending ridges adjacent a back edge of the outer side panels, with at least one of the inner and outer side panels including a cam surface that causes the edge of the inner side panel to deflect inwardly so the groove and ridge can slide into interfitting engagement. 